Method for producing laminated embossed webs

ABSTRACT

A method for producing laminated embossed webs useful as toweling, napkins, placemats and the like. The method employs a novel arrangement of embossing and laminator rolls to achieve a nested configuration of the embossed, inwardly-extending projections, and avoids the speed limitations inherent in prior machines.

United States Patent 1191 Nystrand Feb. 18, 1975 METHOD FOR PRODUCINGLAMINATED [56] References Cited EMBOSSED WEBS UNITED STATES PATENTS [75]Inventor: Ernst Daniel Nystrand, Green Bay, 3,142,599 7/1964Chavannes 1. 161/131 X Wis. 3,414,459 12/1968 Wells 3,547,723 12/1970Gresham 156/209 [73] Assrgnee: Paper Converting Machine Company GreenPrimary Examiner-Charles E. Van Horn [22] Filed; Ap 30, 1973 AssistantExaminer-David A. Simmons pp NO: 355,565 Agent, or FirmDawSon, Tilton,Fallon &

Related US. Application Data [60] Continuation of Ser. No. 24,980, March19, 1970, [57] ABSTRACT abandoned, which 18 a division Of Ser. NO. Amethod for producing laminated embossed webs 1969' 3,556,907- useful astoweling, napkins, placemats and the like.

The method employs a novel arrangement of emboss- [52] U.S. C1 156/209,156/219, 156/291, ing and laminator rolls to achieve a nested configura5 161/131 tion of the embossed, inwardly-extending projections, [51]Int. Cl B31f 1/20 and avoids the Speed limitations inherent in prior[58] Field of Search 156/219, 220, 209, 290, chines 2 Claims, 5 DrawingFigures 1 METHOD FOR PRODUCING LAMINATE EMBOSSED WEBS This applicationis a continuation of my copending application Ser. No. 24,980, filedMar. 19, 1970, now abandoned which in turn was a division of applicationSer. No. 793,430, filed Jan. 23, 1969, now U.S. Pat. No. 3,556,907.

BACKGROUND AND SUMMARY OF INVENTION Embossed toweling has been made inthe past by procedures such as are seen in U.S. Pat. No. 3,414,459.Toweling of this nature has peg-to-peg projections or embossments whichare developed through rotating embossing rolls in synchronism with ahigh degree of precision. This necessarily limits production because thenip defined by the embossing rolls mu st be carefully controlled. inaddition, the width of the machine is necessarily limited because of thepossibility of run-out of the rolls, differential expansion anddeflection along the length thereof due to dimensional differences whichoften are magnified during operation.

Through the provision of two embossing units plus a uniquely positionedlaminator roll, I am simultaneously able to avoid the productionlimitations discussed above and at the same time provide asuperiorembossed laminate.

DETAILED DESCRIPTION The invention is described in conjunction with theaccompanying drawing, in which:

FIG. 1 is a fragmentary schematic view of the inven tive machine aswould be seen from one side;

FIG. 2 is a reduced scale perspective view of the machine of FIG. 1',

FIG. 3 is a fragmentary plan view of the product inssuing from theleft-hand side of FIG. 1, and corresponds to that seen along the sightline 33 applied to FIG. 1;

FIG. 4 is an enlarged scale fragmentary sectional view taken along theline 4-4 applied to FIG. 3; and

FIG. 5 is a fragmentary perspective view of the adhesive applicator rollseen in FIG. 2.

In the illustration given, the numeral generally designates a framewhich is seen to include a pair of side elements for rotatablysupporting a plurality of rolls. These rolls can be appreciated betterfrom a consideration of FIG. 2 wherein a first embossing unit is made upof a platen roll 11 and an embossing roll 12. A second embossing unitconsists of the embossing roll 13 and the platen roll 14. Each embossingroll 12 and 13 has a steel surface with a plurality ofoutwardlyextending projections formed thereon. Advantageously, theprojections may number from about 10 to about 200 per square inch, andmay project upwardly from the surface about 0.01 inches to about 0.05inches whereby approximately 10% to about 75% of the surface of a web isembossed. For this purpose, the platen rolls may be covered with anysuitable material currently used in the art, i.e., rubber, as shown, orpaper, etc. The platen rolls may also be made of steel with matingprotrusions.

The numeral 15 designates a web issuing from an unwind stand (not shown)and passing around an idler roll 16, and thereafter into the nip definedby the rolls 11 and 12. The projections on the roll 12 developcorresponding projection 17 seen in the web 15 in FIG. 3. Adhesive isapplied to some or all of the high points of these projections by meansof the adhesive-applying unit generally designated 18 and which is seento include a fountain 19 and a series of transfer rolls 20, 21 and 22which are driven in conventional fashion. As seen in FIG. 5, theadhesive-applying roll 22 has provided thereon a pattern of raisedsurfaces as at 220. This results in applying adhesive to less than allof the high points of the protrusions provided by the embossing unitwhich includes rolls 11 and 12. Through the use of a colored adhesive, adecorative, eye-pleasing pattern can be produced which is visiable bythe user of the web product. A certain amount of the adhesive penetratesthrough the web 15 to make the pattern visible, and further, the web isgenerally at least translucent and almost transparent so that distinctcolor impressions can be obtained. For example, in the web productdesignated T in FIG. 3, six of the depressions, as at 17a, have beenshaded to show a red coloration in a generally hexagonal design. This isreadily achieved through the use of suitably engraved plates on theplate cylinder applicator roll 22.

In analogous fashion, an upper web is designated 23 and is seen to bepassing around an idler roll 24 before being embossed by the coaction ofrolls l3 and 14. The projections on the roll 13 develop correspondingprojections in the web 23 the developed projections being designated 25in FIG. 3. Thereafter the webs are united in passing into the hip 26defined by the rolls l2 and 27. The roll 27 is the so-called marryingroll and is seen to have a surface covered with resilient material 28such as rubber having a rating in the range of about 50 to about 90Durometer A.

In the illustration given, a steel roll is employed for the laminatorroll 27 and the covering was achieved through initially gluing a layerof spiral-wrapped, hard, rubber-covered tape. The roll surface was thenground to present a smooth surface against the embossing roll 12. Thepressure at the nip 26 was adjusted to the range of 50-60 pounds perlinear inch, which was satisfactory for the starch-adhesive used inlaminating. Alternatively, a smooth steel roll could be employed as themarrying roll 27 without any covering, but the thin, hard, rubbercovering permits operation without the accuracy otherwise requiredinsofar as run-out and straightness is concerned. The covering, which,in production machines, may be of the order of /2 inch thick andDurometer rubber, eliminates the danger of mushrooming the smallembossing elements on the roll 12 when the usual nip pressures arepresent. An additional advantage from the use of a resilient coveredroll is the lack of a need for a separate drive. The numerousprotrusions on the embossing roll. 12 drive the laminator 27 withoutdifficulty.

The web issuing to the left of the roll 27 is generally designated T andcorresponds to the showing in FIG. 3. The adhesive which is applied onlyto the high points of the projections 17 results in glue bonds of thetype designated 29 in FIG. 4. In some cases I prefer to have the heightof the projections 25 somewhat less so that a gap 30 exists between theprojection 25 and the confronting portion of the web 15. In any event,the projections 17 are rigidly supported during laminating.

As seen in FIG. 2, the plurality of rolls 11-14, 16, and 24 are allrotatably supported on the frame 10 as by means of suitable bearings,one of which is designated 31. The rolls are rotated in synchronism bymeans of gears 32 from a power source (not shown).

Referring again to FlG. 1, it will be noted that there is a distinctclearance between the rolls l2 and 13, which means that no problems ofwidth limitation due to run-out, deflection, bearing heating, and thelike are encountered, as well as the fact that there does not have tobe'perfect register or synchronism between the rolls 12 and 13..

A wide variety of webs may be employed satisfactorily in the practice ofthe invention, depending upon the ultimate product. As illustrated, theproduct may be toweling having a basis weight of about 7 to about 50pounds per ream (3,000 square feet). Other webs, such as film, foil,etc., may be employed, again depending upon the ultimate product.Products such as placemats, napkins, and the like are advantageouslyprovided on the inventive machine. In any event, there is developed anadvantageous beam action during the integration by virtue of thesupported projections 17 on the web 15. Also, I prefer to employ theroll 27 with a diameter somewhat different from that of roll 12 so thatthe high points do not occur in the same position each revolution,providing, in effect, a hunting of the high points relative to theresilient covered roll 27.

It will be appreciated also that considerable leeway is provided in theembossing pattern. As is illustrated, the patterns in the two rolls areidentical, so that there is a perfect interlacing or nesting of theprojections of one web relative to the projections of the other web.However, one web may have more of an open pattern of projection so thatseveral projections on the other web will be accommodated during theinterlacing. The projections may be circular, triangular, oval,hexagonal, diamond-shaped, or have any other of a multiple choice ofshapes. Orientation of the pattern of the projections on the two websmay be similar or dissimilar as desired. Choice of shapes of theprojections may be similar or dissimilar on the two webs. In any event,there is provided a unique nested-embossment type of web product wherethe nesting results in substantial bulk or air space and as can beappreciated from a consideration of FIG. 4; in other words, theembossments in one web do not occupy all of the space betweenembossments in the other web. This additionally makes possible thedevelopment of the attractive color pattern through the selectiveapplication of adhesive, and, to this, an additional advantage accruesin that less adhesive is required since only a predetermined number ofprotrusions receive adhesive.

While in the foregoing specification a detailed description of anembodiment of the invention has been set down for the purpose ofillustration, many variations in the details herein given may be madewithout departing from the spirit and scope of the claims.

I claim:

1. A method for producing laminated embossed webs comprising separatelyembossing two webs each with a pattern of projections of about 10 toabout 200 per square inch and a height of about 0.01 to about 0.05inches, applying adhesive to at least some of the projections of one ofsaid webs while the same is supported on an embossing roll, orientingsaid webs so that the projections face each other and interlace witheach other so as to provide air spacing in the interlacing, and applyinga linear laminating pressure by passing said webs through the nipdefined by a marrying roll and the embossing roll which provided theprojections on said one web to join said webs while said one web has theprojections thereon supported and while maintaining the hardness of saidmarrying roll and the pressure in said nip to prevent distortion of theprojections of the other said webs.

2. The method of claim 1 in which said laminating pressure is of theorder of 50-60 pounds per'linear

1. A method for producing laminated embossed webs comprising separatelyembossing two webs each with a pattern of projections of about 10 toabout 200 per square inch and a height of about 0.01 to about 0.05inches, applying adhesive to at least some of the projections of one ofsaid webs while the same is supported on an embossing roll, orientingsaid webs so that the projections face each other and interlace witheach other so as to provide air spacing in the interlacing, and applyinga linear laminating pressure by passing said webs through the nipdefined by a marrying roll and the embossing roll which provided theprojections on said one web to join said webs while said one web has theprojections thereon supported and while maintaining the hardness of saidmarrying roll and the pressure in said nip to prevent distortion of theprojections of the other said webs.
 2. The method of claim 1 in whichsaid laminating pressure is of the order of 50-60 pounds per linearinch.